Universal Flange Holding Wrench

205-072 (15-030A)

Lifting Bracket, Engine

303-122 (21-068A)

Socket, Cylinder Head Bolt

303-392 (21-167)

Mounting Stand

303-435 (21-187)

Mounting Bracket for 303-435

303-435-06 (21-031B)

Mounting Plate for 303-435-06

303-435-11 (21-146C)

1. Install the crankshaft main bearing shells.

2. NOTE:The bearing cap numbering starts from the front of the engine, to which the arrows also point.
   • Lubricate the main bearing journals and bearing shells with clean engine oil.
   • Make sure that the cylinder No. 1 is in top dead center (TDC) position.

3. NOTE:The grooves in the crankshaft thrust half-washers must be face outwards.

4. NOTE:The connecting rod numbering starts from the front of the engine. The arrow on the piston crown points towards the front of the engine.
   Using a suitable piston ring compressor, install the pistons.
   • Lubricate the pistons and cylinder liners with clean engine oil.
   • Distribute the piston ring end gaps uniformly around the circumference. This also applies to the elements of the oil scraper ring.
   • Using the handle of a hammer, press pistons No. 1 and 4 into the cylinders. The connecting rod bearing journal must be at bottom dead center (BDC).
   • Check the bearing shells are clean and dry and install them in the associated connecting rods and bearing caps.
   • Turn the crankshaft through 180 degrees and install pistons No. 2 and 3.

5. CAUTION:Install new connecting rod retaining bolts.
   NOTE:The connecting rods and connecting rod bearing caps have the same numbering.
   • Lubricate the bearing shells and journals with clean engine oil.
   • Tighten the crankshaft bearing cap retaining bolts in two stages.
   • Stage 1: 4 Nm.
   • Stage 2: 90 degrees.

6. Install the oil pan baffle.

7. Install the timing chain guide, timing chain tensioner arm and the crankshaft sprocket.

8. NOTE:The mark on the crankshaft timing sprocket and the single colored link of the timing chain must line up.

9. CAUTION:Only install the oil pump together with the crankshaft pulley.
   CAUTION:When installing a new oil pump, do not remove the crankshaft pulley or the assembly clip before installation.
   NOTE:Install a new oil pump gasket.
   NOTE:A new oil pump is supplied as an assembly with a crankshaft front seal and a crankshaft pulley.
   NOTE:Do not tighten the oil pump retaining bolts at this stage.

10. Using the special tool, tighten the crankshaft pulley retaining bolt.
    • Remove the assembly clip.

11. NOTE:The oil pump sealing flange must be within ± 0.20 mm of the cylinder block bottom sealing flanges.
    Using a suitable straight edge, align the oil pump to the cylinder block sealing flanges.

12. NOTE:Install new pre-sealed bolts in positions 1 and 3.
    • Tighten the bolts in the sequence shown.

13. NOTE:Make sure that the O-ring seal is correctly seated.

14. CAUTION:Do not remove the installation sleeve before installation.
    NOTE:Install a new crankshaft rear seal carrier.
    NOTE:A new rear seal carrier is supplied preassembled on an installation sleeve.
    NOTE:Do not touch the dust lip and the sealing lip.
    NOTE:The sealing lip must be free of oil.
    NOTE:Make sure that the dowel pins are correctly seated.

15. CAUTION:Install the oil pan gasket within five minutes of applying the sealant.

16. NOTE:Do not fully tighten the oil pan retaining bolts at this stage.
    Using a suitable straight edge, align the oil pan to the cylinder block.
    • Maximum oil pan face underflush: 0.25 mm.
    • Maximum oil pan face protrusion: 0.10 mm.

17. Tighten the oil pan retaining bolts in the sequence shown (stage 1).

18. Tighten the oil pan retaining bolts in the sequence shown (stage 2).

19. Install the adaptor plate.

20. Install the flywheel.

21. Install the water pump.

22. Install the water pump pulley.

23. NOTE:Install a new cylinder head gasket.
    NOTE:Install new cylinder head bolts.
    NOTE:Guide the timing chain through the cylinder head and secure it to the cylinder head.
    Using the special tool, install the cylinder head.
    • Tighten the cylinder head bolts in the sequence shown in four stages.
    • Stage 1: Tighten bolts 1 through 10 to 40 Nm.
    • Stage 2: Tighten the front two bolts (M8) to 15 Nm.
    • Stage 3: Tighten the front two bolts (M8) bolts to 45 degrees.
    • Stage 4: Tighten bolts 1 through 10 to 120 degrees.

24. NOTE:The camshaft sprocket timing mark must be in the 12 o’clock position.
    NOTE:The camshaft sprocket timing mark and the marked links of the timing chain must line up.
    Install the timing chain to the camshaft sprocket.
    • The camshaft sprocket timing mark must be at the 12 o’clock position with cylinder No. 1 at TDC.

25. Using the special tool, install the camshaft sprocket.

26. Install the oil level indicator and tube.
    • Apply sealant to base of the oil level indicator tube.

27. Install the timing chain hydraulic tensioner.

28. NOTE:Install a new coolant flow control housing gasket if necessary.

29. NOTE:Install a new oil filter adaptor gasket.

30. Install a new oil filter.

31. Install the crankshaft position (CKP) sensor.

32. Install the oil pressure switch.

33. Install the knock sensor (KS).

34. NOTE:Install a new valve cover gasket if necessary.

35. NOTE:Install a new intake manifold gasket if necessary.

36. Connect the camshaft position (CMP) sensor and engine coolant temperature (ECT) sensor electrical connectors.

37. Connect the positive crankcase ventilation (PCV) hose to the intake manifold.

38. Install the generator retaining bracket.

39. Install the generator.

40. Install the engine front mount bracket.

41. Install the special tool.

42. Remove the special tools.

43. NOTE:Install a new exhaust manifold gasket and new exhaust manifold retaining nuts.
    • Tighten the retaining nuts in the sequence shown in two stages.
    • Stage 1: 15 Nm
    • Stage 2: 20 Nm

44. Install the exhaust manifold heat shield.